Building construction assembly of structural modules

ABSTRACT

A building construction assembly composed of factory-manufactured thermoplastic structural modules which when interconnected at a building site then create the entire shell of an edifice having side walls and a roof. Each module which is formed of a pair of parallel panels bridged by transverse webs is provided on either side along its length with a pair of flexible catch flanges projecting from the panels. When assembling these modules to create the shell of the edifice, adjacent modules are interconnected in coplanar relation by a double-faced joiner on each face of which is a pair of teeth. When one face of the joiner is pressed against a side of a module, its catch flanges then flex to snap into and behind the teeth to connect the joiner to this module. The other face of the joiner is similarly connected to the side of an adjacent module whereby the modules are then interconnected in coplanar relation. When it becomes necessary to interconnect four modules in a cross formation, use is then made of a square, quad-faced joiner on each face of which are a pair of teeth which are engageable by the catch flanges projecting from the side of the module to be joined to this face.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to a building construction assemblycomposed of plastic structural modules which are interconnectable tocreate the shell of a residential or other edifice, and in particular toan assembly of this type in which the modules are interconnected bysnap-in joiners to create the walls of the shell.

2. Status of Prior Art

The need for low cost housing that is available on short notice becomesmost pressing when there is an influx of people into a community who arein search of such housing but cannot afford the cost of standardhousing, nor can they wait out the prolonged period it normally takes toconstruct a standard house.

Such a situation arose at the conclusion of World War II when thousandsof veterans returned to their towns and villages to rejoin or acquirewives and to find a suitable residence for their families. U.S. Pat. No.1,958,124 is addressed to this situation, for it discloses a buildingconstruction assembly composed of factory-manufactures block-like hollowsteel modules which when interconnected at a building site create thebasic shell of a livable residence.

But the commercial acceptance of a construction assembly of steelmodules was not widespread, for it was discouraged by the need to weldtogether a multitude of such modules. This requirement addedsubstantially to the cost of erecting the steel sbell of the edifice andthe time it took to do so.

Of greater prior art interest is the 1999 U.S. Pat. No. 5,729,944 to DeZen which deals with an assembly of interconnectable thermoplasticstructural components, adapted to create the shell of an edifice, asdoes a construction assembly in accordance with the present invention.

The structural components disclosed in the De Zen patent are eachprovided along its length with grooves adapted to mate with interlockingflanges of a box connector serving to interconnect adjacent components.A serious drawback of the De Zen arrangement is that it is necessary toslide the elongated structural components into the box connectors and itis difficult to do so at a building site. Also of prior art interest areDe Zen U.S. Pat. Nos. 5,706,620 and 5,974,751 which show constructionassemblies similar to those in the De Zen '944 Patent.

There are known also building structures disclosed in U.S. Pat.5,247,773. In this patent are described modular structural componentsextruded from plastic. The structures are used for building a wall,ceiling, roof etc. The structures can be connected by virtue of male andfemale means provided on the middle of short, transversal walls of themodules. For this purpose the male component of one module has resilientflanges that can be forced into a corresponding female slot of theadjacent module. Relevant to the present invention is the embodimentshown in FIG. 9,10 depicting a dedicated joiner consisting of two malelocking protrusions facing in opposite directions and adapted forinsertion into corresponding female depressions made in the modules. Thedisadvantage of this solution lies in the fact that relatively highforces should be applied to join the modules, since the force is to beapplied perpendicularly to the transversal wall of the module and itshould be sufficient to deflect both resilient flanges of the malecomponent, the outcome of which is that assembly becomes complicated andinconvenient. This renders the assembling complicate and inconvenient.Furthermore, the disposition of the female depressions on the middle ofthe transverse wall allows to join the modules merely in side-by-siderelationship and not in a cross relationship.

SUMMARY OF THE INVENTION

In view of the foregoing, the main object of this invention is toprovide a building construction assembly composed offactory-manufactured thermoplastic modules capable of beinginterconnected quickly and without difficulty at a building site toerect the permanent shell or framework of a residential structure orother edifice.

More particularly, an object of the invention is to provide a buildingconstruction assembly of the above type in whose modules areinterconnected by snap-in double-faced and quad-faced joiners, themodules being joined together simply by a snap-in action.

Among the significant advantages of this invention are the following:

-   -   1st. The snap-in joiners obviate the difficulties encountered in        prior art assemblies in which it is necessary to slide the        modules with respect to their joiners in order to interconnect        them, whereby assembly and erecting of a structure substantially        does not require applying force or using tools;    -   2nd. The snap-in joiners interconnect the modules so that no        free spaces exist therebetween in walls constructed of these        modules, and further, the joiners are concealed between        adjoining modules;    -   3rd. The snap-in joiners facilitate the erection of the complete        edifice shell at a building site, even a complex edifice, in a        matter of hours, rather than days or weeks;    -   4th. The cost of erecting an edifice shell by interconnecting        modules by means of snap-in joiners is relatively low, yet the        interconnections are strong and durable;    -   5th. A shell created by interconnected modules in accordance        with the invention can readily be anchored on a ground pad at a        building site, making it possible thereafter to quickly complete        the internal structure of the edifice.

Briefly stated, these objects are attained in a building constructionassembly composed of factory-manufactured thermoplastic structuralmodules which when interconnected at a building site then create theentire shell of an edifice having side walls and a roof. Each module isformed by a pair of parallel panels bridged by transverse webs andprovided on either side along its length with a pair of flexible catchflanges projecting from the panels.

When assembling these modules to create the shell of the edifice,adjacent modules are interconnected in coplanar relation by adouble-faced joiner; on each face of which is a pair of teeth. When oneface of the joiner is pressed against the side of a module, its catchflanges then flex to snap into and behind the teeth to connect thejoiner to this module. The other face of the joiner is similarlyconnected to the side of an adjacent module whereby the modules are theninterconnected in coplanar relation.

When it becomes necessary to interconnect four modules in a crossformation, use is then made of a square quad-faced joiner on each faceof which is a pair of teeth to engage the catch flanges of the modulejoined to this face.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the invention as well as other objects andfeatures thereof, reference is made to the annexed drawings wherein:

FIG. 1 is a perspective view of a one-story residence constructed on abuilding site, the shell of which is formed from an assembly ofinterconnected plastic modules in accordance with the invention;

FIG. 2 illustrates the keel of the gable roof of the building shown inFIG. 1;

FIG. 3 illustrates one of the modules included in the assembly;

FIG. 4 is a quad-faced square joiner connecting the second module to athird module at right angles thereto;

FIG. 5 is an end view of the double-faced joiner;

FIG. 6 a plan view of a double-faced joiner for interconnecting adjacentmodules in coplanar relation;

FIG. 7 illustrate how the joiner interconnects adjacent modules; and

FIG. 8 is a plan view of the quad-faced square joiner.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to FIGS. 1 and 2 of the drawings, shown therein is aone-story house 10 suitable as a family residence, the shell of whichdefines the walls and roof of the house. The shell is erected at abuilding site by interconnecting an assembly of structural modules 11 inaccordance with the invention.

These modules are factory-manufactured on a mass production basis toproduce an assembly of modules appropriate to the architecture of theedifice. The assembly is then shipped to the building site at which itis only necessary to interconnect the modules 11 to erect the side walls12 and 13 of the house and its gabled roof 14. The modules forming thewalls are structured to provide rectangular openings to accommodate adoor 15 and windows 16 and 17.

The gabled roof 14 is formed by interconnected modules 11 forming angledsides at whose peak is a keel 18. Overlying keel 18 and covering itsjunctions with the angled sides of the roof is a flashing 19 whichserves to waterproof the roof.

The shell of house 10 is anchored by anchor rods or other means to arectangular concrete ground pad P. The architecture of house 10illustrated in FIGS. 1 and 2 is by way of example only. In practice, theassembly of modules may be tailored to create an edifice of any designhaving side walls which are vertical, horizontal or angled. When acolony of prefabricated houses is planned, each erected by an assemblyof modules in accordance with the invention, it is then desirable thatthe houses in the colony have different design to avoid regimentationand to provide a more natural community.

Each module 11, as shown in FIG. 3 is extruded of high-strengththermoplastic material such as PVC, polyethylene or polycarbonate in themanner disclosed in the above-identified De Zen patents. In practice,the plastic material may be fiber-reinforced by glass, carbon or otherfibers which act to strengthen the module.

Module 11 consists of parallel panels 20 and 21 bridged by a row ofequispaced transverse webs 22 integral with the panels to form alight-weight structure highly resistant to compressive and bendingforces. Because the modules are not heavy, they are easy to handle atthe construction site. The space between transverse webs 22 may befilled with foamed thermal isolating material or may including wiringand other installations of the constructions.

The air space between the panels when the modules are interconnected toform a wall may be used to accommodate electrical wiring or plumbingpipes. The entrapped an space imparts thermal insulation properties tothe wall.

Extending from the opposite ends of module panels 20 and 21 are flexiblecatch flanges C1 and C2 which run the full length of the module and areprovided with bent-in catches. Flanges C1 and C2 project beyond the webs22 at the opposite ends of the web row, and because the catch flangesare flexible, they can be deflected in the manner to be later explainedto catch onto the teeth of a module joiner.

To join adjacent modules 11A and 11B which are in line with each otherso that they are in coplanar relation, there is provided, as shown inFIGS. 4, 5 and 6, a double-faced joiner J having a pair of opposingrectangular faces F1 and F2. Projecting from face F1 is a pair ofparallel teeth TA and TB having a trapezoidal cross section, only theouter side of the teeth being sloped to function as a ramp. Projectingfrom face F2 which is opposite face F1 is a like pair of teeth TA andTB.

The dimensions of double-faced joiner J complement those of the modules11A and 11B to be interconnected. Hence when face F1 of joiner J ispressed against the side of module 11A, its projecting teeth TA and TBengage catch flanges C1 and C2 on the side of this module, causing theflanges to flex and snap into and behind the teeth and thereby connectjoiner J to module 11A. And when face F2 of joiner J is pressed againstthe side of the adjacent module 11B to connect the joiner thereto,modules 11A and 11B are then interconnected in a side-by-side, coplanarrelation as shown in FIG. 7.

When the modules are interconnected by double-faced joiner J, thedouble-faced joiner J is then confined within the space between the endwebs 22 of the adjacent modules as shown in FIG. 4. Hence there is nofree space between the modules when they are interconnected to form aplanar wall of the edifice.

When it is necessary to join a planar wall to another planar wall atright angles thereto, then as shown in FIGS. 4 and 8, one must use forthis purpose a four-faced square joiner SJ each rounded corner of whichis defined by a pair of teeth TX and TY at right angles to each other.Thus the opposing parallel faces 23 and 24 of the quad-faced squarejunction SJ are each provided with a pair of teeth TX, while theopposing parallel faces 25 and 26 which are at right angles to faces 23and 24 and are each provided with a pair of teeth TY.

Snapping into the pair of teeth in each face of square joiner SJ are theflexible catch flanges C1 and C2 extending from the side of a module.Thus FIG. 4 shows a third module 11C joined to a face of square junctionSJ so that it is at right angles to the second module 11B. A fourthmodule (not shown) can be joined to the face 25 of the junction so thatit too is at right angles to the third module, and a fifth module (notshown) can be joined to face 23 so that it is in line with the secondmodule. Thus when modules are connected to all four faces of the squarejoiner SJ they are in symmetrical cross formation.

The double-faced and four-faced make it possible to create the shell ofan edifice having planar walls at right angles to each other. If thegeometry of the shell is such as to require a joiner for providing anacute angle between one wall and another, the four-faced joiner for thispurpose then has an appropriate parallelogram shape.

While there has been shown an assembly of interconnectable modules forerecting the shell of an edifice, it is to be understood that manychanges may be made therein without departing from the scope of theinvention as defined by the appended claims. Thus the modules, insteadof being extruded of thermoplastic material may be formed of extrudedaluminum.

1. A building construction assembly comprising: a) a group of modules(11), which are interconnectable to create a shell of an edifice (10),each module (11) in the group is defined by a pair of parallel laterallongitudinal panels (20,21) having opposite ends, wherein said lateralpanels are bridged by at least one transversal web (22) extendingbetween the panels, b) a joiner (J,SJ) for interconnecting modules inthe group said joiner having at least two faces (F1,F2) detachablyconnectable to the opposite ends of the module characterized in thateach lateral panel (20,21) terminates at either of the opposite endsthereof with a flexible catch region (C1,C2)having a long portion and ashort, bent-in portion and, either face (J,SJ) of the joiner is providedwith a pair of teeth (TA,TB,TX,TY)adapted, when a face of the joiner ispressed against either of the catch regions (C1,C2) of the module tourge the long portion to flex and the bent-in portion to snap into andbehind the teeth (TA,TB,TX,TY) and thus to connect either of oppositeends of the module (11) to the joiner (J,SJ).
 2. An assembly as setforth in claim 1, in which the joiner (J)has two opposite faces(F1,F2),either of which is provided with a pair of teeth (TA,TB) adapted tointerconnect two modules (11A,11B) in side-by-side, coplanarrelationship.
 3. An assembly as set forth in claim 1, in which thejoiner (SJ) has four faces (23,24,25,26) arranged in a square formation,said faces are adapted to interconnect four modules in a crossrelationship.
 4. An assembly as set forth in claim 1, in which saidmodules (11) in the group are made in a factory and are adapted to bejoined together at a building site to create said shell.
 5. An assemblyas set forth in claim 4, in which said modules (11), wheninterconnected, are adapted to create an edifice shell having walls(12,13) and a roof (14).
 6. An assembly as set forth in claim 4, inwhich each module (11) is formed of a thermoplastic material.
 7. Anassembly as set forth in claim 6, in which the thermoplastic material isextruded to define a pair of parallel lateral panels (21) and a row oftransverse webs (22) bridging the panels.
 8. An assembly as set forth inclaim 7, in which either of said catch regions (C1,C2) extends from therespective lateral panel (21) and is integral therewith.
 9. An assemblyas set forth in claim 8, in which the long portion of either of thecatch regions (C1,C2) is flush with the respective lateral panel (21).10. An assembly as set forth in claim 1, in which the shell of theedifice is anchored on a concrete pad (P) at a building site.
 11. Anassembly as in claim 2, in which said teeth (TA,TB) have a trapezoidalcross section with one sloping side, which, when engaged by either ofsaid catch regions (C1,C2), is adapted to urge the long portion of thecatch region to flex and the bent-in portion to snap behind the teeth.12. A joiner (J,SJ) adapted to interconnect at least two modules (11),each of them having a pair of parallel lateral panels (21) bridged by atleast one transversal web (22), wherein either of said lateral panelsterminates by a flexible catch region (C1,C2) provided with a longportion and a short, bent-in portion, characterized in that said joiner(J,SJ) has at least two faces (F1,F2,23,24,25,26), each of the facesbeing provided with a pair of teeth (TA,TB,TX,TY), which are engageableby either of the catch regions (C1,C2) and when a face(F1,F2,23,24,25,26) of the joiner is pressed against the catch region,the teeth (TA,TB,TX,TY) are adapted to urge the long portion of thecatch region to flex and the ben-in portion to snap into the teeth. 13.A joiner (J) as set forth in claim 12, having a pair of faces (F1,F2),said faces are opposite to each other.
 14. A joiner (SJ) as set forth inclaim 12, having four faces (23,24,25,26) arranged in a squareformation.